A belt fixing device includes an endless belt member, an excitation coil and a deterioration detection unit. The endless belt member includes a metal layer. The excitation coil heats the metal layer by electromagnetic induction. The deterioration detection unit detects deterioration of the metal layer of the belt member through the excitation coil.
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1. A belt fixing device comprising:
an endless belt member that includes a metal layer;
an excitation coil that heats the metal layer by electromagnetic induction;
a detection piece disposed in an area of the belt member where a bending strain of the detection piece is larger than that of the metal layer; and
a deterioration detection unit configured to detect, through the excitation coil, change in a characteristic value of the detection piece, which has a correlation with deterioration of the metal layer.
2. The belt fixing device according to
3. The belt fixing device according to
4. The belt fixing device according to
5. The belt fixing device according to
6. The belt fixing device according to
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1. Technical Field
This invention relates to a fixing device for heating, pressurizing, and fixing an unfixed toner image, used with an electrophotographic-type image forming apparatus such as a copier, a printer or a facsimile and in particular to a belt fixing device of an electromagnetic (magnetic) induction heating system and an image forming apparatus using the belt fixing device.
2. Description of the Related Art
Hitherto, in an electrophotographic-type image forming apparatus such as a copier or a printer, for example, a photosensitive member formed like a drum (photosensitive drum) is uniformly charged and is exposed to light, which is controlled based on image information, so as to form an electrostatic latent image on the photosensitive drum. After the electrostatic latent image is formed into a visible image (toner image) with toner and the toner image is transferred from the photosensitive drum directly to a recording medium or after the toner image is once primarily transferred to an intermediate transfer body and is secondarily transferred from the intermediate transfer body to a recording medium, a fixing device fixes the toner image onto the recording medium.
A fixing device of a heating roller system is widely used as a fixing device used in such an image forming apparatus.
In addition to such a heating roll system, a fixing device of an electromagnetic induction heating system has also been known.
In the fixing device of an electromagnetic induction heating system, a roller or a thin fixing belt with a metal layer is used as a fixing member to be heated. When the thin fixing belt is used as the fixing member, the fixing belt can be warmed up in an extremely short time.
The main factor of determining the life of the fixing device of the electromagnetic induction heating system using the fixing belt as described above is a metal layer of a heat generation layer. Generally, since the heat generation layer subjected to electromagnetic induction heating is made of metal, the metal is fatigue-broken because of repeated deformation in the nip portion. As a result, the metal layer does not serve the function as the heat generation layer. This point in time leads to the end of the life of the fixing device of the electromagnetic induction heating system using the fixing belt.
An effective life detection method has not yet been developed for the fixing device of the electromagnetic induction heating system.
According to an aspect of the invention, a belt fixing device includes an endless belt member, an excitation belt and a deterioration detection unit. The endless belt member includes a metal layer. The excitation coil heats the metal layer by electromagnetic induction. The deterioration detection unit detects deterioration of the metal layer of the belt member through the excitation coil.
Exemplary embodiments of the invention will be described in detail below with reference to accompanying drawings wherein:
Referring to the accompanying drawings, exemplary embodiments of the invention will be described below.
To begin with, the schematic configuration of an image forming apparatus to which a belt fixing device according to this exemplary embodiment of the invention is applicable will be described with reference to
As schematically shown in
The fixing device 7 according to this exemplary embodiment of the invention is implemented as a belt fixing device of an electromagnetic induction heating system including a fixing belt 71 and a pressurization roll 72. The fixing belt 71 is subjected to electromagnetic induction heating and is rotatable. The pressurization roll 72 is in pressure-contact with the fixing belt 71 while being parallel to the axis of the fixing belt 71.
The image forming apparatus to which the invention is applicable is not limited to the exemplary embodiment described above. For example, the invention may also be applied to an image forming apparatus of the rotary type in which an image forming unit are placed on a rotation body. Alternatively, the invention may be applied to an image forming apparatus of the tandem type in which image forming units are placed side by side.
Next, the belt fixing device 7 according to this exemplary embodiment of the invention will be described in detail with reference to
As shown in
As shown in
A flexible and heat-resistant material excellent in mechanical strength, such as a fluorocarbon resin, a polyimide resin, a polyamide resin, a polyamideimide resin, a PEEK resin, a PES resin, a PPS resin, a PFA resin, a PTFE resin or FEP resin may be used as the base layer 71a. The thickness of the base layer 71a is in a range of about 10 μm to about 100 μm, preferably, in a range of about 50 μm to about 100 μm (for example, 75 μm) from the viewpoint of providing compatibility between strength and flexibility and shortening the startup time. In this exemplary embodiment, a polyamide resin having 50 μm in thickness is used.
The conductive layer 71b is a heat generation layer, which generates heat by the electromagnetic induction action of a magnetic field produced by the electromagnetic induction heating device 75. The conductive layer 71b may be formed of a metal layer, such as iron, cobalt, nickel, copper, aluminum or chromium, having a thickness in a range of about 1 μm to about 30 μm. A material is selected so that the conductive layer 71b has a peculiar resistance value to generate sufficient heat by electromagnetic induction. In this exemplary embodiment, the conductive layer 71b is made of copper having 10 μm in thickness.
The protection layer 71c is a layer for making adjustment so that the heat generation layer (conductive layer) 71b is located in a neutral plane in the thickness direction of the fixing belt 71. The “neutral plane” is a plane in which bending strain does not occur even if the fixing belt 71 deforms. Any material may be used as the protection layer 71 so long as the protection layer has a predetermined Young's modulus and thickness. Considering the manufacturing cost and the heat capacity, it is desirable that the protection layer should be formed of a metal layer. In this exemplary embodiment, nickel having 5 μm in thickness is used as the protection layer 71c.
That is, in this exemplary embodiment, both of the conductive layer (heat generation layer) 71b and the protection layer 71c are formed of metal layers.
The elastic layer 71d may be made of silicone rubber, fluorocarbon rubber or fluoro silicone rubber, which has good heat resistance and good heat conductivity and has a thickness in a range of about 10 μm to about 500 μm, preferably in a range of about 50 μm to about 500 μm. In this exemplary embodiment, silicone rubber having 300 μm in thickness is used as the elastic layer 71d.
The surface release layer 71e is a layer for coming in direct contact with an unfixed toner image transferred onto a recording material P. Thus, the surface release layer 71e needs to be made of a material having good releasability. Examples of the material of the surface release layer 71e may include perfluoro-alkoxyfluoro plastics (PFA), polytetrafluoroethylene (PTFE), silicone resin, silicone rubber and fluorocarbon rubber. In this exemplary embodiment, PFA having 30 μm in thickness is used as the surface release layer 71e.
Further, the fixing belt 71 of this exemplary embodiment includes a detection piece 71S having a thin plate shape (thin film) serving as a deterioration detection unit. The detection piece 71S is disposed in a place where when the whole belt is bent, bending stain of the detection piece 71S is larger than that of the metal layer such as the heat generation layer 71b and/or the protection layer 71c. Specifically, the detection piece 71S is disposed outside the neutral plane of the fixing belt 71c in the thickness direction of the fixing belt 71c (that is, on the front-face side where the fixing belt 71c faces the pressurization roll 72) and outside the heat generation layer 71b and/or the protection layer 71c, which are the metal layers. The detection piece 71S has an area of about 5 mm square to about 30 mm square and has a thickness in a range of about 3 μm to about 30 μm. Furthermore, the detection piece 71S is disposed outside an area R through which a sheet of paper having a maximum size passes (in the axial direction). The detection piece 71S is used to detect deterioration of the heat generation layer 71b and/or deterioration of the protection layer 71c so as to determine the life of the fixing belt 71. Any material can be selected as the detection piece 71S appropriately so long as the selected material has correlation with deterioration of the metal layer (the heat generation layer 71b and/or the protection layer 71c ) caused by bending of the fixing belt 71. The metal material, which is the same as the heat generation layer 71b or the protection layer 71c , may be adopted as the detection piece 71S. The “same kind of metal” means that if the metal layer is formed of plural metal layers (for example, a copper heat generation layer and a nickel protection layer), the detection piece is made of the same metal as any of the plural metal layers.
In this exemplary embodiment, the detection piece 71S is disposed outside the neutral plane of the fixing belt 71 in the thickness direction thereof and outside the metal layers such as the heat generation layer 71b and/or the protection layer 71c. However, the detection piece 71S may be disposed in a place inside the fixing belt 71 in the thickness direction thereof so long as bending strain of the detection piece 71S is larger than that of the metal layer such as the heat generation layer 71b and/or the protection layer 71c.
Next, the pressurization roll 72 includes a metal cylindrical cored bar 72a, an elastic layer 72b and a surface release layer 72c. The metal cylindrical cored bar 72a serves as a core material. The elastic layer 72b has heat resistance, is made of silicone rubber or fluorocarbon rubber, and is disposed on the surface of the cored bar 72a. The surface release layer 72c formed the outermost surface of the pressurization roll 72. The pressurization roll 72 and the press pad 73 form a fixing nip portion while the pressurization roll 72 and the press pad 73 are clamping the fixing belt 71 therebetween.
The pressurization roll 72 is in pressure-contact with the press pad 73 through the fixing belt 71 with a load of 20 kgf. The pressurization roll 72 is driven circularly by a motor M. Also, the fixing belt 71 is driven to follow the rotation of the pressurization roll 72. When the recording material P to which an unfixed toner image is transferred is passed through the fixing nip portion between the fixing belt 71 and the pressurization roll 72, the unfixed toner image is fixed onto the recording material P by heat and pressure to form a fixed image.
The press pad 73 includes a pedestal 73a and an elastic member 73b. The pedestal 73a is made of a metal such as SUS or iron, or is made of a resin having a heat resistance. The elastic member 73b made of silicone rubber is bonded to the pedestal 73a. The press pad 73 presses the fixing belt 71 against the pressurization roll 72. The nip portion is formed between (i) the elastic member 73b and the fixing belt 71 and (ii) the pressurization roll 72. In this exemplary embodiment, to decrease mutual sliding frictional force between the press pad 73 and the fixing belt 71, a lubricant such as heat-resistant grease is applied to the nip portion between the press pad 73 and the fixing belt 71.
Each guide member 76 is made of a heat-resistant resin. Each guide member 76 includes a support part, an inner guide part 722 and an edge guide part 723. The support part 721 supports the pad support member 74 and is fixedly supported at its end in the axial direction. The inner guide part 722 regulates the side edge of the fixing belt 71. The edge guide part 723 is fitted into the corresponding end of the fixing belt 71 in the axial direction of the fixing belt 71.
The electromagnetic induction heating device 75 is placed along the outer peripheral surface of the fixing device 71 with a gap having about 2 mm from the outer peripheral surface of the fixing device. The electromagnetic induction heating device 75 heats the conductive layer of the fixing belt 71 by electromagnetic induction to generate heat. The electromagnetic induction heating device 75 has a main part including a pedestal, an excitation coil 75b and an excitation circuit 75c. The pedestal 75a has a curved surface along the outer peripheral surface of the fixing belt 71. The excitation coil 75b is supported on the pedestal 75a. The excitation circuit 75c supplies an AC current to the excitation coil 75b.
The pedestal 75a is made of a material having insulating properties and heat resistance. Examples of the material of the pedestal 75a may include a phenol resin, a polyimide resin, a polyamide resin, a polyamideimide resin and a liquid crystal polymer resin.
The excitation coil 75b is formed into a turn part 75d (shape of the excitation coil 75b viewed from the above), which is a litz wire wound plural times (e.g. 11 times) into a closed loop shape such as a rectangle shape, an oval shape or an ellipsoid shape and extending over the substantially entire region in the axial direction of the fixing belt 71. The litz wire is a bundle of several copper wires each having a diameter φ of 0.5 mm and insulated from each other by a heat-resistant insulating material (for example, polyimide resin, polyamideimide resin, etc.,). The excitation coil 75b is fixed with an adhesive to thereby be fixed to the pedestal 75a while the shape of the excitation coil 75b is maintained.
In the electromagnetic induction heating device 75, when an AC current is supplied from the excitation circuit 75c to the excitation coil 75b, a magnetic flux is generated and vanished repeatedly in the surroundings of the excitation coil 75b. The frequency of the AC current is in a range of about 10 kHz to about 50 kHz, for example. In this exemplary embodiment, the frequency of the AC current is set to 30 kHz. When the magnetic flux crosses the conductive layer 71b of the fixing belt 71, an eddy current occurs in the conductive layer 71b so as to produce a magnetic field to prevent change in the magnetic field and Joule heat occurs with power proportional to the skin resistance of the conductive layer 71b (W=I2R) for heating the fixing belt 71 to a predetermined temperature.
Next, a method for detecting deterioration of the fixing belt 71 using the detection piece 71S according to this exemplary embodiment of the invention will be described.
Generally, if the thickness of the metal layer 71b of the heat generation layer is in a range of about 1 μm to about 30 μm as in this exemplary embodiment, as the thickness is larger, induction heating occurs more easily, that is, the power factor is larger. Therefore, when the detection piece 71S rotates with the rotation of the fixing belt 71 and crosses the excitation coil 75b, the power factor varies depending on whether or not the detection piece 71S exists just below the excitation coil 75b. When the detection piece 71S exists just below the excitation coil 75b, the highest power factor is achieved.
Then, this exemplary embodiment uses the excitation coil 75b, which serves as an electromagnetic induction heating unit, as a deterioration detection unit. The exemplary embodiment monitors change in the power factor of the detection piece 71S through the excitation coil 75b. Thereby, it is made possible to detect deterioration of the metal layer 71b, 71c of the fixing belt 71.
Let the rotational period of the fixing belt 71 be T0. As understood from
The detection piece 71S is disposed outside the heat generation layer 71b and/or the protection layer 71c and outside the neutral plane of the fixing belt 71 in the thickness direction thereof. Therefore, when the fixing belt 71 is deformed in the fixing nip portion, bending strain occurring in the detection piece 71S becomes larger than that occurring in the heat generation layer 71b and/or the protection layer 71c. As a result, if the fixing belt 71 becomes deformed repeatedly in the fixing nip, deterioration (crack) occurs on the detection piece 71S more early than the heat generation layer 71b and/or the protection layer 71c. That is, as schematically shown in
When a crack occurs in the detection piece 71S, the maximum value of the power factor detected through the excitation coil 75b becomes small as compared with the case where no crack occurs in the detection piece 71S. That is, as schematically shown in
That is, according to the deterioration detection unit according to this exemplary embodiment, change in the power factor of the detection piece 71S is monitored through the excitation coil 75b. Thereby, it is made possible to detect the precise life responsive to the use state of the fixing belt 71, based on the predetermined correlation between (i) the life of the heat generation layer 71b and/or the protection layer 71c of the fixing belt 71 and (ii) the life of the detection piece 71S.
Next, a specific examination result using such a deterioration detection unit will be described.
To conduct an examination, first the nickel detection piece 71S having 3 μm in thickness is disposed via a thin primer layer on the nickel protection layer 71c (having 5 μm in thickness) of the fixing belt 71 and outside the area R through which the sheet of paper having the maximum size passes in the axial direction. The position of the neutral plane is the center of the copper heat generation layer 71b having 10 μm in thickness by adjusting the Young's modulus of each layer. The distance between the neutral plane and the nickel surface of the protection layer 71c is 10 μm. The distance between the neutral plane and the surface of the detection piece 71S is 13 μm.
Therefore, when the fixing belt 71 is deformed, a ratio of bending strain occurring in the surface of the protection layer 71c to bending strain occurring on the surface of the detection piece 71S becomes 1:1.3 in theory.
Although the bending strain and the crack occurrence cycle do not have a linear relation with each other in a wide range, it may be said that 30% in difference is almost a linear relationship in terms of the strain level in the fixing nip portion. Therefore, letting the number of cycles until a crack starts occurring in the detection piece 71S in the long-hour fixing operation, namely, the number of cycles until the maximum value of the power factor starts decreasing be Ch, it can be predicted that a crack will occur on the protection layer 71c, namely, the end of the life will be reached in 0.3×Ch cycles from the time when the crack occurs in the detection piece 75S.
Therefore, a message indicating that the fixing belt 71 is just before it will reach the end of the life may be displayed at an appropriate point in time after the number of crack occurrence cycles Ch.
Actually, occurrence of a crack in the protection layer 71c of the fixing belt 71 in the vicinity of 1.3×Ch cycles under a predetermined fixing condition can be verified. Accordingly, it can be verified that the deterioration detection unit according to this exemplary embodiment of the invention can detect the precise life of the fixing belt 71 responsive to the use state of the fixing belt 71.
In the exemplary embodiment described above, the deterioration detection unit detects the life of the fixing belt 71 by detecting change in the power factor of the detection piece 71S. However, the invention is not limited to such a deterioration detection unit. A deterioration detection unit according to another exemplary embodiment may monitor change in the magnetic characteristic value of the detection piece 71S having a correlation with the life of the metal layer 71b, 71c of the fixing belt 71 through the excitation coil 75b. For example, change in the inductance of the detection piece 71S may be monitored through the excitation coil 75b, to thereby detect deterioration of the fixing belt 71.
Further, in the above described exemplary embodiment, the detection piece 71S made of the same kind of metal as the metal layer 71b, 71c is disposed in the fixing belt 71 so as to detect deterioration of the metal layer 71b, 71c from the viewpoint of stably detecting deterioration of the metal layer with higher accuracy. However, from the viewpoint of detecting deterioration of the metal layer 71b, 71c with a simpler configuration using a device configuration of a related art, the detection piece 71S may be omitted and the voltage/current of the excitation coil 75b may be monitored. According to this configuration, deterioration of the metal layer 71b, 71c of the fixing belt 71 can also be determined. That is, in so doing, when an actual crack occurs in the metal layer 71b, 71c, for example, the inductance of the crack occurrence part changes and the voltage/current induced to the excitation coil 75b changes. Thus, although it is inferior to use of the detection piece 71S in detection of deterioration of the metal layer 71b, 71c at rapid and stable timing with accuracy, it is made possible to determine deterioration of the fixing belt 71 according to the same device configuration as that in the related art by monitoring the voltage/current inducted to the excitation coil 75b. This configuration contributes to drastic cost reduction and device miniaturization as compared with a configuration provided with a special sensor.
Itoh, Kazuyoshi, Naito, Yasutaka, Ohhara, Hideaki
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